Hose anti-collapse ribs, systems and methods

ABSTRACT

An integral hose anti-collapse rib comprises a unitary body having a first cantilevered portion curved in a first direction. This first cantilevered portion defines a first end. A second cantilevered portion is curved in a direction opposite the direction of the first cantilevered portion, in a direction facing the first cantilevered portion. The second cantilevered portion also defines a second end disposed at an opposite extent of the rib from the first end. The hose anti-collapse rib also comprises a locking mechanism that locks the first end of the rib to the second end of the rib, such that the first and second cantilevered portions together form a generally circular shape. However, in a relaxed state in which the locking mechanism is not engaged, the rib preferably defines a non-circular, generally spiral shape.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to hoses, more particularly to hosessubject to vacuum, and specifically to hose anti-collapse rib systemsand methods.

2. Description of the Prior Art

Turbocharger intake hoses and other applications that require vacuumresistance typically require thick walls, stiff materials, built-insprings, or internal springs to resist collapse. These solutions areexpensive, difficult to install, and heavy. Because internal springshave a high surface area and have no interference fit with the hose,vibration and high air flow can cause them to move out of place, eveninto the engine, possibly even into the intake port. Even minimal springmovement can damage, or interfere with the operation of, engine controlsensors. Regardless, movement of such a spring could result in hosecollapse. Furthermore, built-in springs often require hand lay-upmanufacturing. Disposition of springs within hose can causediscontinuities that may lead to premature hose failure. Suchdiscontinuities might include: voids in hoses in which springs aremolded-in; shear stress in the rubber of the hose due to the greatdifference in stiffness between the spring and the hose rubber; unevenloading of clamps due to an underlying spring; and/or vibration failuresdue to the spring wearing through the rubber of the hose.

SUMMARY

The present invention is directed to hose anti-collapse ribs, systemsand methods which provide resistance to collapse in turbocharger intakehoses and other vacuum hose applications. In particular, embodiments ofthe present invention are directed to an internally disposed stiffeningrib that expands and locks into place on the hose ID. This solutionallows relatively inexpensive, thinner wall hose to be used inrelatively higher vacuum applications. The rib may be made of relativelythin, low cost molded plastic. The material might be selected to beresistant to rusting, and resistant to other chemicals which couldinclude ethylene glycol, re-circulated fuel, oil, etc. Advantageously,such ribs cause less flow restriction than a typical internal spring.Unlike springs, the ribs expand and preferably lock into the hose. Thepresent ribs also have minimal cross-sectional area exposed to the flowstream within a hose, minimizing the force that the flowing fluidapplies, further assuring that the rib will stay in place.

In accordance with embodiments of the present invention an integral hoseanti-collapse rib might comprise a unitary body having a firstcantilevered portion curved in a first direction. This firstcantilevered portion defines a first end. A second cantilevered portionis curved in a second direction opposite the first direction of thefirst cantilevered portion, that is, in a direction facing or towardsthe first cantilevered portion. The second cantilevered portion alsodefines a second end disposed at an opposite extent of the rib from thefirst end. Such embodiments also preferably comprise a locking mechanismthat locks the first end of the rib to the second end of the rib, suchthat the first and second cantilevered portions together form agenerally circular shape. However, in a relaxed state in which thelocking mechanism is not engaged, the rib preferably defines anon-circular, generally spiral shape.

The rib may also include one or more interference ridges defined in anexterior surface of the cantilevered portions. This ridge may, incertain embodiments be adapted to deform a hose in which the rib isdisposed to provide an interference interlock between the rib and thehose when the rib is expanded within the hose. An interference ridgecould consist of one or more interference projections of any shapeadapted to engage the inner surface of the hose when the rib is expandedwithin the hose.

The locking mechanism might comprise complementary tabs defined by theends, wherein each of the tabs is an end portion of the respectivecantilevered portion having a thickness approximately one-half thethickness of the respective cantilevered portion. In such embodimentsthe tab defined by the first cantilevered portion may be generallyaligned with an inner portion of the first cantilevered portion and thetab defined by the second cantilevered portion may be generally alignedwith the outer portion of the second cantilevered portion. The tabs maycomprise a leading edge defined by one of the cantilevered portions anda complementary leading edge receptive notch defined by the other of therib's cantilevered portions.

In certain embodiments a locking ridge may be defined in an outsidesurface of one of the tabs in certain embodiments with a complementarygroove, adapted to receive the locking ridge, defined in an insidesurface of the other of the tabs. The groove may extend beyond the othertab along an inside surface of the respective cantilevered portion. Thecooperative edge and notch lock the rib in the expanded position,possibly in conjunction with the cooperative locking ridge and groove.

In operation, a hose anti-collapse rib such as described above may bedeployed by disposing the hose anti-collapse rib within a hose that isto be subject to vacuum or similar collapsive forces and expandingopposite curved cantilevered portions of the rib to form the rib into agenerally circular shape in contact with an inner surface of the hose.This expanding may be accomplished in certain embodiments by indexing aridge defined in an outer surface of one tab in a groove defined in aninner surface of the other tab. More specifically, the expanding mayinclude sliding the ridge defined in the outside surface of the one tabin a groove defined in an inside surface of the other cantileveredportion, guiding the ridge into the groove defined in the inner surfaceof the other tab. Preferably the hose anti-collapse rib is locked in thegenerally circular shape. Such locking may, in accordance with certainembodiments of the present invention, include mating a first tab definedby an end of a first of the cantilevered portions with a second tabdefined by an end of a second of the cantilevered portions. Movement ofthe rib within the hose may be prevented by engaging an interior surfaceof the hose with a ridge defined in an outer surface of the rib.

A method for forming such an anti-collapse rib might include molding arib body having a first curved cantilevered portion and a second curvedcantilevered portion. This molding might include forming tabs in ends ofthe cantilevered portions. The tab formed in the end of the firstcantilevered portion may be formed to have approximately half thethickness of the remainder of the first cantilevered portion.Correspondingly, the tab formed in the end of the second cantileveredportion may be formed to have approximately half the thickness of theremainder of the second cantilevered portion.

Preferably, the second cantilevered portion has a curvature deflected inan opposite direction, toward the end of the first cantilevered portion.An end of the second cantilevered portion may be positioned under thefirst cantilevered portion such that the rib body forms a generallycircular shape that can be expanded into a larger generally circularshape. Preferably the larger generally circular shape is more circularthan the initial circular shape. Consistent with the above discussion,the ends of the rib body may lock in place upon expansion of the ribbody in the larger generally more circular shape.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter which form the subject of the claims of the invention. Itshould be appreciated by those skilled in the art that the conceptionand specific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures for carrying out the samepurposes of the present invention. It should also be realized by thoseskilled in the art that such equivalent constructions do not depart fromthe spirit and scope of the invention as set forth in the appendedclaims. The novel features which are believed to be characteristic ofthe invention, both as to its organization and method of operation,together with further objects and advantages will be better understoodfrom the following description when considered in connection with theaccompanying figures. It is to be expressly understood, however, thateach of the figures is provided for the purpose of illustration anddescription only and is not intended as a definition of the limits ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and form part ofthe specification in which like numerals designate like parts,illustrate embodiments of the present invention and together with thedescription, serve to explain the principles of the invention. In thedrawings:

FIG. 1 is a perspective view of an embodiment of the present hoseanti-collapse rib;

FIG. 2 is a front view of the embodiment of FIG. 1 with the rib disposedin a relaxed state;

FIG. 3 is a front view of the embodiment of FIG. 1 with the rib disposedin a collapsed state, prepared for insertion in a hose;

FIG. 4 is a front view of the embodiment of FIG. 1 with the ribexpanded;

FIG. 5 is a fragmented, generally cross sectional view of the rib body,taken generally along line 5-5 of FIG. 4;

FIG. 6 is a fragmented environmental view showing an embodiment of thepresent hose anti-collapse rib disposed in a turbocharger intake hose;and

FIG. 7 is a fragmented view of the locking mechanism of a ratchetembodiment of the present invention.

DETAILED DESCRIPTION

Embodiments of present hose anti-collapse rib 100 preferably employ adual cantilever limb configuration, where the rib is molded in theapproximate shape of two integral limbs one with a curvature greaterthan the other, deflected or curved in opposite, facing directions. Thisprovides a non-circular, somewhat spiral, rib, such as illustrated inFIGS. 1 and 2, having the general shape of a “6” or a “9”. If first limb101 is thereafter positioned under limb 102 the generally circular,spiral, collapsed ring configuration shown in FIG. 3 is obtained. Uponexpansion of rib 100, the expanded and locked (more) circular shapeshown in FIG. 4 is obtained.

In greater detail, the illustrated embodiment of an integral hoseanti-collapse rib 100 might be a unitary body having a firstcantilevered portion or limb 101. First limb 101 is preferably curvedand defines a first end 105. A second cantilevered portion or limb 102is preferably curved in a direction opposite the direction of the firstcantilevered portion, as shown in FIGS. 1 through 4. As will beappreciated from FIGS. 1 and 2, first limb 101 preferably has lesscurvature (i.e. a larger radius) than second rib 102. Second limbportion 102 preferably also defines second end 106, which may be viewedas being disposed at an opposite extent of rib 100 from first end 105.Preferably, as may be best seen in FIG. 5, all edges of the rib aretapered or chamfered to keep the hose from being damaged duringexpansion of the rib or by the expanded rib itself. Taper 107 ofinternal edges of rib 100 preferably minimize flow disruption created bydeployed rib 100.

The illustrated embodiment of rib 100 also includes hose interferenceridge 109 extending outwardly from an exterior surface of rib 100. Incertain embodiments, interference ridge 109 is adapted to deform a hosein which the rib is deployed to provide a heavy “interference interlock”between the rib and the hose. For example, with attention directed toenvironmental FIG. 6, when rib 100 is expanded within hose 601(illustrated as a turbocharger intake hose), interference ridge 109contacts inner surface 602 of hose 601, deforming it, as evidenced byexternal bulge 603 in hose 601. This contact between interference ridge109 and inner hose surface 602 provides the aforementioned interferenceinterlock, which prevents movement of rib 100 within hose 601, includingbracing the rib to help prevent rotation of the rib within the hose ormigration of the rib along the length of hose 601 (toward turbo charger605). In particular, the interference interlock helps assure that underheat and pressure, the hose will not expand beyond the diameter of therib and cause the rib to move out of place, such as toward the impellerof turbo charger 605. It will be appreciated that various embodiments ofthe present invention may employ more than one interference ridgeextending outwardly from the exterior surface of the rib to enhance theabove-described interference interlock. Likewise, an interference ridgecould comprise one or more interference projections of any discreteshape, size, and/or arrangement or pattern adapted to engage the innersurface of the hose when the rib is expanded within the hose. Also, itshould be appreciated that adhesive or some other method to attach theexpanded rib to the interior of the hose wall can be used to ensure thatthe rib does not move within the hose.

The illustrated embodiment of rib 100, also preferably includes lockingmechanism 110 that locks first end 105 of rib 100 with second end 106 ofrib 100, particular when rib 100 is disposed in the expandedconfiguration shown in FIGS. 4 and 6. Thereby, in the expanded andlocked configuration best seen in FIG. 4, first and second cantileveredlimb portions, 101 and 102, together form a generally circular shape.However, in a relaxed state in which locking mechanism 110 is notengaged, rib 100 preferably defines the generally spiral shape seen inFIG. 3.

Locking mechanism 110 might comprise complementary tabs 115 and 116defined by ends 105 and 106, respectively. Each of tabs 115 and 116 arean end portion of the respective cantilevered limb portion 101 or 102.Preferably each tab has a thickness that is approximately one-half thethickness of the rest of rib 100. In the illustrated embodiment the tabseach comprise a leading portion of the respective cantilevered limb andare complementary, when disposed in the loading configuration shown inFIG. 3 or the deployed configuration shown in FIGS. 4 and 6. Thus, aleading portion of limb 101 defines receptive tab 115, adapted toreceive opposite tab 116 upon expansion of rib 100. In the illustratedembodiment, tab 115, defined by first cantilevered portion 101, might begenerally aligned along an inner thickness or surface of the firstcantilevered portion. Complementarily, tab 116, defined by secondcantilevered portion 102, might be generally aligned with an outerthickness or surface of the second cantilevered portion.

Illustrated locking mechanism 110 further employs edge 120, defined bythe leading edge of second limb 102 and receptive notch 121 defined atthe base of tab 115 in first limb 101. Further, illustrated lockingmechanism 110 may also employ edge 123, defined by the leading edge offirst limb 101 and receptive notch 124 defined at the base of tab 116.In the expanded configuration shown in FIGS. 4 and 6, leading edges 120and 123 are disposed in respective receptive notches 121 and 124 to lockrib 100 in the generally circular expanded state.

Illustrated locking mechanism 110 also employs alternative locking ridge125 extending outwardly from an outside surface of tab 115 andcomplementary groove 126 (best seen in FIG. 1) defined in an innersurface of tab 116, which is adapted to receive locking ridge 125.Groove 126 may (discontinuously) extend beyond notch 124 of tab 116,along an inside surface of cantilevered limb portion 102 to act as aguide for locking ridge 125 during expansion of rib 100 from the spiralcondition shown in FIG. 3 to the expanded state of FIGS. 4 and 6. Thisguiding might also aid in alignment of rib portion 101 with rib portion102 during deployment. Once deployed, locking ridge 125's indexing withgroove 126 helps prevent lateral slippage of tabs 115 and 116, furtherensuring the integrity of expanded rib 100. Also, in the expandedposition, locking ridge 125 might add support to the portion ofinterference ridge 109 that extends onto the surface of tab 102 byfilling in groove 126.

A method for forming illustrated anti-collapse rib 100 might includemolding a one-piece rib body having integral first and second curvedcantilevered limb portions 101 and 102. This molding might includeforming tabs 115 and 116 at the ends of cantilevered limb portions 101and 102. Consistent with the description above, tab 115 formed in theend of the first cantilevered portion 101 might be formed to haveapproximately half the thickness of the remainder of the firstcantilevered portion. Correspondingly, tab 116 formed in the end ofsecond cantilevered portion 102 may be formed to have approximately halfthe thickness of the remainder of the second cantilevered portion. Asalso described above, second cantilevered portion 102 preferably has atighter curvature than first cantilevered portion 101, deflected orcurved in an opposite direction, toward the end of the firstcantilevered limb portion. Following initial forming or manufacture, rib100 has the initial “6” shape shown in FIGS. 1 and 2. As described ingreater detail below, the end of first cantilevered portion 101 may bepositioned under the second cantilevered portion 102 such that the ribbody forms a generally circular, spiral shape that can be expanded intoa larger generally circular shape. Preferably the larger generallycircular shape is more circular than the spiral shape. In otherembodiments, the deployed or expanded generally circularly shape may bemore oval or the like in order to fit within a hose of generally ovalshape or other shape that is not precisely circular.

Hose anti-collapse rib 100 described above may be deployed generally byfollowing the configurations illustrated in FIGS. 2 through 4. A ribhaving the general manufactured shape shown in FIGS. 1 and 2 may bedeflected into the general spiral shape shown in FIG. 3 by passing firstlimb portion 101 under second rib portion 102, or conversely passingsecond limb portion 102 over first rib portion 101, such as bydeflecting one or both rib portion laterally. As a result, rib limb 101is “loaded” against limb 102. Hose anti-collapse rib 100, in thespiral-shaped configuration of FIG. 2, may be disposed within a hosethat is to be subject to vacuum or similar collapsive forces, such asturbocharger intake hose 601. Then rib 100 may be expanded into theconfigurations shown in FIGS. 4 and 5 by expanding oppositely curvedcantilevered limb portions 101 and 102 to form the rib into a generallycircular shape that preferably contacts inner surface 602 of hose 601.This expanding may be accomplished, or facilitated in some embodiments,such as those illustrated, by indexing locking ridge 125 defined in anouter surface of tab 101 in groove 126 defined in an inner surface oftab 116 and limb portion 102. More specifically, the expanding mayinclude sliding locking ridge 125 in the portion of groove 126 definedin the inner surface of limb 102, guiding locking ridge 125 into theportion of groove 126 defined in the inner surface of tab 106.Regardless, the loading of limb 101 against limb 102 will facilitatelocking tabs 115 and 116 together. Preferably, hose anti-collapse rib100 is thus disposed in a generally circular shape and may be lockedinto this shape, at least in the illustrated embodiments, by mating edge120 of second tab 116 with notch 121 defined at the base of first tab115, and the indexing of locking ridge 125 with groove 126. Thusdeployed, movement of rib 100 within hose 601 will be arrested invarious embodiments, such as the illustrated embodiment, by engaginginterior surface 603 of hose 601 with interference ridge 109, defined inthe outer surface of rib 100.

As can be appreciated, the locking mechanism described is onlyillustrative. Various embodiments of the present invention might notemploy the locking ridge and groove. Other example embodiments mightemploy additional locking structures that might include bonding the tabstogether after installation by means such as adhesive or ultrasonicwelding. Such bonding might be employed in the place of, or in additionto, the interlocking provided by the illustrated edge/notch and/orlocking ridge/groove locking mechanisms, or the like. Other embodimentsof the present invention might employ an external ring, corresponding tothe rib, such that the hose wall is deformed between the external ringand the internal rib to aid in keeping the rib locked in place.

The embodiment of the present invention illustrated in FIGS. 1 through 6utilizes tabs with leading edges that lock into notches at a designatedrib diameter, resulting in a constant thickness rib. However, ratchetingrib embodiments, such as rib 700 of FIG. 7, that could deploy or open tomultiple diameters, may also be an attractive option. Such a ratchetingdesign could possibly be spring-loaded, such as by forming the limbportions with an outwardly expanding bias, to automatically expand intoplace once positioned in the hose. In such a ratchet embodiment “dogs”701 might be defined on a surface of one tab and “pawls” 702 might bedefined on the facing surface of the other tab, such that the dogs andpawls engage in a one-way, locking fashion. If such an embodiment isspring loaded, as the hose in which the rib is disposed expands, due totemperature or fatigue, the rib would ratchet outward, tighter.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made herein without departing from the spirit andscope of the invention as defined by the appended claims. Moreover, thescope of the present application is not intended to be limited to theparticular embodiments of the process, machine, manufacture, compositionof matter, means, methods and steps described in the specification. Asone of ordinary skill in the art will readily appreciate from thedisclosure of the present invention, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the present invention.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps.

What is claimed is:
 1. A hose anti-collapse rib comprising: a firstcantilevered portion curved in a first direction and defining a firstend; a second cantilevered portion curved with a different curvaturethan said first cantilevered portion and in a direction facing saidfirst direction and defining a second end disposed at an opposite extentof said rib from said first end; means for locking said first end tosaid second end such that said first and second cantilevered portionstogether form a generally circular shape, and an interference ridgedefined in an exterior surface of said cantilevered portions, whereinsaid interference ridge is adapted to deform a generally flexible hosein which said rib is disposed to provide an interference interlockbetween said rib and said hose when said rib is expanded within saidhose.
 2. The rib of claim 1 wherein in a relaxed state in which saidmeans for locking is not engaged, said rib defines a non-circularspiral.
 3. The rib of claim 1, wherein said means for locking comprisescomplementary tabs defined by said ends.
 4. The rib of claim 3, whereineach of said tabs is an end portion of said respective cantileveredportion and each of said tabs has a thickness approximately one-half thethickness of said respective cantilevered portion.
 5. The rib of claim4, wherein said tab defined by said first cantilevered portion isgenerally aligned with an outer portion of said first cantileveredportion and said tab defined by said second cantilevered portion isgenerally aligned with an inner portion of said second cantileveredportion.
 6. The rib of claim 3, wherein one of said tabs comprise aleading edge and another of said tabs comprises a complementary leadingedge receptive notch.
 7. The rib of claim 3, wherein said locking meansfurther comprises adhesive securing said tabs to one another.
 8. The ribof claim 3, further comprising: a locking ridge defined in an outsidesurface of one of said tabs; and a complementary groove defined in aninside surface of said other of said tabs, adapted to receive saidridge.
 9. The rib of claim 8, wherein said groove extends beyond theother tab along an inside surface of the respective cantileveredportion.
 10. The rib of claim 1, wherein said means for lockingcomprises a ratcheting mechanism.
 11. The rib of claim 1, whereinexternal edges of said cantilevered portions are tapered.
 12. The rib ofclaim 1, wherein internal edges of said cantilevered portions aretapered.
 13. A method comprising: disposing a hose anti-collapse ribwithin a generally flexible hose subject to vacuum; expanding oppositecurved cantilevered portions of said rib to form said rib into agenerally circular shape in contact with an inner surface of said hose;locking said hose anti-collapse rib in said generally circular shape;preventing movement of said rib within said hose by engaging an interiorsurface of said hose with a interference ridge defined in an outersurface of said rib; and preventing movement of said rib within saidhose by adhering an exterior surface of said rib to an interior surfaceof said hose.
 14. The method of claim 13 wherein, said locking comprisesmating a first tab defined by an end of a first of said cantileveredportions with a second tab defined by an end of a second of saidcantilevered portions.
 15. The method of claim 14, wherein said lockingfurther comprises indexing a ridge defined in an outer surface of one ofsaid tabs in a groove defined in an inner surface of the other of saidtabs.
 16. The method of claim 15, wherein said expanding furthercomprises sliding said ridge in a groove defined in an inside surface ofthe other of said cantilevered portions, guiding said ridge into saidgroove defined in said inner surface of said other tab.